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Summary

Fear of change—we all experience it. Some accept change immediately, some gradually adapt, while others may never get there. Whether it’s poor leadership, the inability to change, or pure ego, this Shingo Prize-winning book explores this perplexing commitment to inefficiency.

Winner of a 2013 Shingo Prize!

The Psychology of Lean Improvements: Why Organizations Must Overcome Resistance and Change the Culture examines the psychology behind why businesses avoid Lean transformations. It investigates why businesses cling to the eight deadly wastes and why they still find ways to place continuous improvement on the back burner.

Frequently sought out for his expertise in Lean manufacturing, Chris Ortiz has been featured in a number of trade publications and on the television show Inside Business with Fred Thompson. In this book, Mr. Ortiz breaks down the fear of change within executives and organizational leaders. He examines the psychology of dysfunction, provides insight into why so many businesses fall short in creating visions for growth and prosperity, and identifies tools that can help you address resistance to change.

Detailing implementation techniques with a proven track record for success, the book considers specific strategies that can be helpful towards improving your company and changing its culture—including cellular manufacturing, total productive maintenance, setup reduction, Kanban, visual communication, and in-line production. It explains how to get started on your Lean transformation, describes why an economic downturn might be a good time to embrace Lean, and warns of the dangers behind failing to do so.

Chris A. Ortiz is the founder and president of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. Watch Chris has being interviewed on Inside Business with Fred Thompson on CNN Headline News.

What Have We Done for Our Customers Today?Dangers of Not Going Lean in a Down Economy Business Is Good, Why Improve? Business Is Good, We Must Improve Business Is Poor, Why Improve? Business Is Poor, We Must ImproveChanging into a Lean Leader Acknowledge and Involve Your Staff Provide an Environment in Which People Can Be Successful Do Not Humiliate Anyone Who Works for You Create an Environment Where Mistakes Are Okay Do Not Hide behind Your Position Be Approachable Admit Your Mistakes Listen in a Way That Encourages Employees to Talk to You Be Clear in Your Requests Stand behind Your People Be a Good CommunicatorLeadersNeed an ROI Training Team Building People Development Strategic PlanningWorld-Class Products Need World-Class ProcessesYou Are the Creator of Your Business Reality

The Psychology of Waste

Psychology of OverproductionPsychology of OverprocessingPsychology of Motion and TransportationPsychology of InventoryPsychology of DefectsPsychology of WaitingPsychology of Human Potential "I’m Paid by the Hour" No Investment in the People People Are ExpendablePsychology of Waste: Conclusion

The Psychology of Dysfunction

Misconception of Working Hard Speed!Living with Waste Living with Overproduction Setup Quality Problems Machines IssuesLiving with MotionLiving with TransportationLiving with Overprocessing Administrative Functions Extra Steps and Redundant Effort Inefficient Machines Inability to Identify a Completion PointLiving with DefectsLiving with WaitingLiving with Inventory Facility Space Production Process

Making Change Happen with 5S

5S and Visual Control Sort Set in Order How to Make a Shadow Board Personal Tools: Dilemma or Solution? Tool Check Cards Right Sizing during Set in Order Examples of Right SizingShineStandardizeSustain Human Will End of the Cleanup Procedures Daily Walkthroughs 5S Audit 5S Tracking IncentivesPsychology of 5S

Author(s) Bio

Chris A. Ortiz is the founder and president of Kaizen Assembly, a Lean manufacturing training and implementation firm in Bellingham, Washington. Chris has been featured on Inside Business (http://www.youtube.com/watch?v=LMm3fVsbPtM) with Fred Thompson on CNN Headline News. He is the author of five books on Lean manufacturing, (see list below). Chris has been featured in dozens of publications including Assembly Magazine, Industrial Engineer, Industrial Management, Metal Finishes, Plant Engineer, Auto Body News, and Collision Repair Magazine to name a few.

Chris Ortiz is a frequent presenter and keynote speaker at conferences such as the IIE Annual Conference and the NACE Automotive Exposition. He has also been interviewed on KGMI radio, and has written numerous articles on Lean manufacturing and business improvement for various regional and national publications. Chris also was recently on the national radio show the American Innovator. He is invited to speak at a few international business and manufacturing conference in Europe every year.

Mr. Ortiz has been trained by the John Costanza Institute of Technology in "Demand Flow Technology" and by the Georgia Institute of Technology for ISO 9001: 2000 Internal Quality Auditing. He is also a member of the Institute of Industrial Engineers and the Society of Manufacturing Engineers. He is the creator of the LEAN Marketplace (www.leanmarketplace.com). Chris Ortiz is considered to be an expert in the field in lean manufacturing implementation.

He is the author of:

Kaizen Assembly: Designing, Constructing, and Managing a Lean Assembly Line (Taylor and Francis, 2006). Now in its second print.

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